System and method for improving exhaust gas recirculation for a turbocharged engine

ABSTRACT

A system and method for delivering EGR to an internal combustion engine is presented. The system can reduce system cost and lower system complexity.

FIELD

The present description relates to improving exhaust gas recirculationfor an internal combustion engine.

BACKGROUND

A system and method for controlling exhaust gas recirculation (EGR) ofan internal combustion engine is described in U.S. Pat. No. 7,043,914.The patent describes an EGR system that has a high pressure loop and alow pressure loop. The system uses two separate EGR valves and twoseparate EGR coolers to provide exhaust gases from upstream aturbocharger turbine to a location downstream the turbochargercompressor or to a location upstream the turbocharger compressor. Thesystem also includes a particulate filter to protect the turbochargercompressor from engine soot. The system purportedly allows large amountsof EGR when the engine is operated at high engine speed and high engineload, thereby reducing engine NOx.

The above-mentioned system can also have several disadvantages. Namely,the system requires control of two different EGR valves. Controlling twodifferent EGR valve may be difficult because the two valves may havedifferent flow characteristics due to deposits and manufacturingtolerances. As a result, EGR rate and engine torque may vary or beunstable when both valves are simultaneously controlled as the enginecontrol system may not have sufficient information to determine whichvalve to adjust. In addition, switching EGR delivered upstream thecompressor to downstream the compressor can cause EGR flow variation inone EGR valve when the other EGR valve is opened or closed. Further, thesystem requires two EGR coolers. Further still, the system enables EGRflow through the compressor simply in response to a temperature sensorand will only allow EGR flow in that path if the temperatures are highenough to regenerate the particulate filter. As a result, the engine mayoperate for a period of time when little EGR flows to the engine becausethe desired EGR flow rate can only be generated in the pre-turbine topre-compressor path; however, low exhaust temperatures will cause flowto be inhibited.

The inventors herein have recognized the above-mentioned disadvantagesand have developed a system and method that offers substantialimprovements.

SUMMARY

One embodiment of the present description includes a system forproviding EGR to an internal combustion engine, the system comprising:an internal combustion engine; a turbocharger comprising a compressorand a turbine; an EGR valve capable of directing exhaust gases from theengine's exhaust to a location in the engine's intake system upstream ofthe compressor or to a location in the engine's intake system downstreamof the compressor; and a controller that provides compensation when thestate of the EGR valve changes from a condition supplying exhaust gasesto downstream the compressor to supplying exhaust gases to upstream thecompressor. This system overcomes at least some disadvantages of theabove-mentioned system.

Supplying EGR to a turbocharged engine can be improved by using a singleEGR valve in place of two separate independently controlled EGR valves.An EGR valve that has multiple flow paths eliminates the need for havingto simultaneously control two valves and multiple EGR coolers. Further,since a single multiple flow path valve flows in only one direction at atime, it is simple to determine when exhaust gas flow to one EGR pathceases and when exhaust flow to a different EGR path begins. As such,compensation can be supplied to reduce engine torque fluctuation andengine NOx. Similarly, engine air-fuel ratio control may be improvedbecause transitions between EGR paths may be more repeatable.

The present description can provide several advantages. Namely, thepresent system can reduce system complexity and cost. Further, thepresent system may reduce engine air-fuel excursions when the engine EGRflow path is changed. Further still, the present system may improvesystem reliability because it has fewer components than other systems.

The above advantages and other advantages, and features of the presentdescription will be readily apparent from the following DetailedDescription when taken alone or in connection with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages described herein will be more fully understood by readingan example of an embodiment, referred to herein as the DetailedDescription, when taken alone or with reference to the drawings,wherein:

FIG. 1 is a schematic diagram of an example engine having aturbo-charger and its control system;

FIG. 2 is a flowchart of an example method for improving EGR for aturbocharged internal combustion engine;

FIG. 3A is an engine map describing one example of different EGR flowmodes;

FIG. 3B is an alternate engine map describing an example of differentEGR flow modes;

FIG. 4 is an example plot illustrating engine conditions during asimulated engine operating schedule.

DETAILED DESCRIPTION

Referring to FIG. 1, internal combustion engine 10, comprising aplurality of cylinders, one cylinder of which is shown in FIG. 1, iscontrolled by electronic engine controller 12. Engine 10 includescombustion chamber 30 and cylinder walls 32 with piston 36 positionedtherein and connected to crankshaft 40. Combustion chamber 30 is showncommunicating with intake manifold 44 and exhaust manifold 48 viarespective intake valve 52 an exhaust valve 54. Each intake and exhaustvalve is mechanically operated and valve opening and closing times arevariable with respect to crankshaft position. Alternatively, the intakeand/or exhaust valves may be electrically or hydraulically actuated.

Intake manifold 44 is also shown having fuel injector 66 coupled theretofor delivering liquid fuel in proportion to the pulse width of signalFPW from controller 12. Fuel is delivered to fuel injector 66 by fuelsystem (not shown) including a fuel tank, fuel pump, and fuel rail (notshown). Alternatively, the engine may be configured such that the fuelis injected directly into the engine cylinder, which is known to thoseskilled in the art as direct injection.

Distributorless ignition system 88 provides ignition spark to combustionchamber 30 via spark plug 92 in response to controller 12. UniversalExhaust Gas Oxygen (UEGO) sensor 76 is shown coupled to exhaust manifold48 upstream of catalytic converter 70. Alternatively, a two-stateexhaust gas oxygen sensor may be substituted for UEGO sensor 76.Two-state exhaust gas oxygen sensor 98 is shown coupled to exhaustmanifold 48 downstream of catalytic converter 70. Alternatively, sensor98 can also be a UEGO sensor. Catalytic converter temperature ismeasured by temperature sensor 77, and/or estimated based on operatingconditions such as engine speed, load, air temperature, enginetemperature, and/or airflow, or combinations thereof.

Converter 70 can include multiple catalyst bricks, in one example. Inanother example, multiple emission control devices, each with multiplebricks, can be used. Converter 70 can be a three-way type catalyst inone example.

Turbo charger 47 is shown in communication with exhaust manifold 48 andintake manifold 44. Fresh air may be compressed by turbo chargercompressor 46, delivered to throttle body 125, and directed to intakemanifold 44. Alternatively, throttle body 125 may be located upstream ofturbo charger compressor 46. If the throttle body is located upstream ofthe compressor, pressure and temperature transducers may be installed inthe intake manifold as well as between the compressor and the throttle(i.e., boost pressure and temperature).

Turbo charger turbine 43 is connected to turbo charger compressor 46 bya shaft. During operation exhaust gases can flow from exhaust manifold48 to turbo charger 47, where expanding exhaust gases can rotate exhaustturbine 43 and compressor 46. Exhaust gases are directed from turbine 43to catalyst 70 for processing. Turbo charger efficiency may be adjustedby varying the vane position actuator 45 of the variable geometry turbocharger. Alternatively, the turbo charger may be a waste gate type ofturbo charger. Also, note that a supercharger may replace theturbocharger if desired.

EGR valve 75 directs exhaust gases from exhaust manifold 48 to theengine's intake system downstream of compressor 46 or to the engine'sintake system upstream of compressor 46. Duct 72 directs exhaust gasesfrom the exhaust system to EGR valve 75. If desired, an exhaust gascooler and/or catalyst (e.g., three-way or oxidation catalyst) may belocated along duct 72 between exhaust manifold (which may includeexhaust piping or ducting) and EGR valve 75. Duct 73 connects one outletof EGR valve 75 to the engine's intake system downstream of compressor46 and throttle 125. Duct 74 connects a second outlet of EGR valve 75 tothe engine's intake system upstream of compressor 46. In an alternativeembodiment, an exhaust gas cooler and/or catalyst may be located alongduct 74 and in between EGR valve 75 and intake duct 42. In still anotherembodiment, an exhaust gas cooler may be located in duct 73.

Controller 12 is shown in FIG. 1 as a conventional microcomputerincluding: microprocessor unit 102, input/output ports 104, andread-only-memory 106, random-access-memory 108, 110 Keep-alive-memory,and a conventional data bus. Controller 12 is shown receiving varioussignals from sensors coupled to engine 10, in addition to those signalspreviously discussed, including: engine coolant temperature (ECT) fromtemperature sensor 112 coupled to water jacket 114; a position sensor119 coupled to an accelerator pedal; a measurement of engine air massfrom mass air sensor 130; EGR valve position from sensor (not shown);exhaust delta pressure across an orifice from sensor 85; a measurementof engine manifold pressure (MAP) from pressure sensor 122 coupled tointake manifold 44; a measurement (ACT) of engine air temperature ormanifold temperature from temperature sensor 117; and engine positionfrom a Hall effect sensor 118 sensing crankshaft 40 position. In apreferred aspect of the present description, engine position sensor 118produces a predetermined number of equally spaced pulses everyrevolution of the crankshaft from which engine speed (RPM) can bedetermined. The controller may determine the amount of overlap betweenintake and exhaust valves as well as fuel timing, spark timing, andthrottle position.

Storage medium read-only memory 106 can be programmed with computerreadable data representing instructions executable by processor 102 forperforming the methods described below as well as other variants thatare anticipated but not specifically listed.

Referring now to FIG. 2, a flow chart of an example routine forcontrolling EGR to a turbocharged engine is presented. At step 201,engine operating conditions are determined. In one embodiment, enginecoolant temperature, time since start, ambient temperature, enginetorque demand, engine speed, EGR valve position, and intake manifoldpressure are determined from sensor data input to an engine controlleror from data that characterizes actuator performance, see FIG. 1 enginecontroller 12 for example. However, additional or fewer operatingconditions may be determined if desired. After engine operatingconditions are determined the routine proceeds to step 203.

Referring now to step 203, the routine selects the desired EGR flow pathin response to engine operating conditions. The EGR valve may inhibitexhaust gas flow or it may be used to regulate the amount of EGR flowingin a first path or in a second path, but EGR flow may only be regulatedin the first or second path at one time. That is, EGR flow is stopped inthe first path when there is EGR flow in the second path and vice-versa.

In one embodiment, the EGR flow path is determined in response to enginespeed and requested engine torque demand. If engine speed and torque arewithin a particular operating region, exhaust gas is extracted from thevehicle's exhaust manifold or pipe from a location in the exhaust systemand delivered to a location in the engine's intake system downstreamfrom the compressor. For example, at medium engine speeds (e.g., enginespeed that may be near 2500 RPM, 3000 RPM, 3500 RPM, 4000 RPM, 4500RPM), exhaust gases can be directed from the exhaust manifold/pipe to alocation in the intake system downstream from the compressor. Further,exhaust gases can be directed from the exhaust manifold/pipe to alocation in the intake system downstream from the compressor when enginespeed is low (e.g., engine speed that may be near 800 RPM, 900 RPM, 1000RPM, 1200 RPM, 1500 RPM, 2000 RPM, 2500 RPM) and at low to medium enginetorque requests (e.g., engine torque request that may be near 10%, 15%,20%, 25%, 30%, 35% of full scale engine output torque).

On the other hand, if engine speed and torque are within a seconddifferent operating region, EGR is extracted from the vehicle's exhaustmanifold or pipe and delivered to a location in the engine's intakesystem upstream from the engine's compressor. For example, at low enginespeeds and high engine torque requests (e.g., engine torque request thatmay be near 40%, 50%, 60%, 75%, 80%, 95%, 100% of full scale engineoutput torque) exhaust gases can be directed from the exhaustmanifold/pipe to a location in the intake system upstream from thecompressor. FIGS. 3 a and 3 b provide examples of two anticipated EGRflow path determination maps that may be used to determine EGR valvestate.

In an alternate embodiment, the EGR flow path can be determined inresponse to a sensed differential pressure between pressure in theexhaust manifold/pipe and the pressure in the intake system. Forexample, if the EGR valve is directing exhaust gases to a location inthe intake system downstream from the compressor and the pressure ratiobetween the exhaust manifold/pipe and the intake manifold downstream thecompressor is less than a predetermined amount or threshold, the routinedecides to change the EGR valve state. Specifically, the EGR valve stateis adjusted so that exhaust gases are directed from the exhaustmanifold/pipe to a location in the intake system that is upstream thecompressor.

On the other hand, if the EGR valve is positioned to deliver exhaustgases upstream the compressor and the pressure difference between theexhaust manifold/pipe and the intake manifold downstream the compressoris greater than a predetermined amount, then the EGR valve can berepositioned so that exhaust gas is directed from the exhaustmanifold/pipe to a location in the intake system located downstream fromthe compressor.

In yet another embodiment, engine speed, engine torque request, anddifferential pressure between the exhaust manifold/pipe and engineintake system are used to determine the EGR valve position.Specifically, the engine speed and requested torque are used to index atable or function that describes a particular EGR flow path, if thepressure differential between the exhaust manifold/pipe and the intakesystem is within a prescribed range, then the EGR valve state changes.If the pressure differential is not within the prescribed range, thenthe EGR valve state is held constant. In this way, the EGR valve stateis confirmed based on engine torque request and differential pressurebetween the exhaust system and the intake system. The routine proceedsto step 205.

In one embodiment, at lower engine speed and torque demands, exhaust gasis directed from the exhaust manifold/pipe to a location in the intakesystem that is downstream from compressor. As the requested enginetorque increases, the EGR valve position changes state based on thedecision in step 203. After the EGR valve changes to its new state,exhaust gases are directed from the exhaust manifold/pipe to a locationin the intake system upstream from the compressor.

At step 205, the routine determines if zero EGR flow is desired. If EGRis to be deactivated the routine sets the EGR valve to the closedposition and exits. Otherwise, the routine proceeds to step 207.

At step 207, the routine determines whether to execute steps to flowexhaust gas to an intake system location that is downstream from thecompressor or to execute steps to flow exhaust gas to an intake systemlocation upstream from the compressor. If at step 203 the routinedetermined to flow exhaust gas to a location in the intake systemdownstream the turbocharger compressor, then the routine proceeds tostep 215. Otherwise, the routine proceeds to step 209.

At step 209, the routine determines if a change to the EGR valve stateis being requested. That is, the routine determines if the EGR valve isbeing repositioned to direct exhaust gases from entering the intakesystem from downstream the compressor to directing exhaust gases toentering the intake system from upstream the compressor.

Note that repositioning the EGR valve to increase or decrease exhaustflow to an individual EGR flow path does not constitute an EGR statechange for the purpose of identifying EGR valve state changes. Rather,an EGR valve state change occurs when the EGR valve position is changed,and as a result, the direction of exhaust gas flow changes from one flowpath to a different flow path (e.g., changing the exhaust gasintroduction location in the intake system from upstream the compressorto a location downstream from the compressor. If an EGR valve statechange is in progress, the routine proceeds to step 211. If not, theroutine proceeds to step 213.

At step 211, the routine adjusts various actuators to compensate the EGRvalve state change. In one embodiment, the engine throttle, EGR valveposition, and spark advance are used to compensate a change in the EGRvalve state. The throttle and spark adjustments are used to compensatetorque changes that may occur when the direction of exhaust gas flow ischanged from a first flow path to a second flow path. The EGR valveposition is adjusted after the EGR valve changes state to account forthe portion of intake system volume that has an exhaust gas fractionthat is different from the desired exhaust gas fraction.

When the EGR valve state is changed to send exhaust gas to a locationupstream the compressor, exhaust gases are directed from the exhaustmanifold/pipe to a location in the intake system upstream from thecompressor. Initially after the EGR valve changes state, the EGR valveis opened to a position that exceeds the position at which the exhaustgas flow rate through the EGR valve provides the desired level of EGR atsubstantially equivalent steady state engine and EGR valve operatingconditions. The EGR valve is then closed to a position that delivers thedesired level of EGR at the present engine operating conditions. Thus,the EGR valve opens to a first position and then closes to a secondposition that is less open than the first position. Engine chargemixture is improved during an EGR valve state change by overshooting thedesired steady state EGR valve position and then moving toward thedesired steady state EGR valve position.

Providing EGR valve position overshoot during an EGR valve state changeincreases the flow of exhaust gas into the intake manifold upstream fromthe compressor. Consequently, exhaust flow into the volume of air in theintake system that exists between the upstream and downstream EGRinjection points is increased. As a result, the newly mixed air andexhaust gas enters the intake manifold at a level that is closer to themixture that existed in the intake manifold before the EGR valve changedstate.

When exhaust gas delivery to the intake system is switched from alocation downstream from the compressor to a location that is upstreamfrom the compressor, the throttle plate position may also be adjusted bybriefly decreasing the throttle opening amount. Decreasing the throttleopening amount allows substantially the same air charge to be drawn intoengine cylinders after the EGR valve state change as before the EGRvalve state change. If the throttle position were to remain atsubstantially the same position during the EGR valve state change, thenadditional air may enter the engine because of the manifold pressuredrop that may be created by deactivating EGR flow. The change inthrottle position can be looked up from empirically determined tablesthat output throttle position as a function of time since EGR valvestate transition, engine torque demand, and engine speed. Alternatively,throttle position can be determined from a model that describes manifoldfilling such as that which is described in U.S. patent application Ser.No. 11/293,729 which is hereby fully incorporated by reference.

Cylinder spark advance can also be adjusted during an EGR valve statetransition when the exhaust delivery location in the intake system ischanged from a location downstream from the compressor to a locationupstream of the compressor. During the EGR valve state transition thecrankshaft angle at which spark is delivered to a cylinder can beretarded to control the engine torque during the valve transition. Thisprovides engine torque compensation when the amount of exhaust enteringengine cylinders may briefly change. Retarding the spark lowers enginetorque and peak cylinder pressure, thereby controlling engine NOxformation during the EGR valve state change. The amount of spark retardand the spark retard duration may be empirically determined and capturedin tables or functions that are interpreted during an EGR valve statetransition. The tables can be indexed by engine operating conditions sothat different amounts and durations of spark retard can be implementedfor different engine operating conditions.

In other embodiments, additional or fewer actuators may be used tocontrol engine torque and emissions during EGR valve state transitions.For example, valve timing may be adjusted by moving camshaft timing withrespect to crankshaft timing. However, it is recognized that someadjustable valve timing devices may operate on a longer time scale thanthrottle or spark adjustments. Variable valve timing may be used toadjust engine torque and internal EGR (i.e., in-cylinder EGR) in systemsthat have large intake manifolds. In one example, intake valve timingand exhaust valve timing are retarded when the entry location of exhaustentering the intake system moves from a location downstream of thecompressor to a location that is upstream from the compressor. Further,exhaust valve timing and intake valve timing may be advanced when theentry location of exhaust entering the intake system is moved from alocation upstream the compressor to a location downstream from thecompressor.

Turbocharger efficiency may also be adjusted during an EGR valve statetransition. For example, when the EGR valve is switched from deliveringexhaust gas from a location in the intake system downstream from thethrottle body and compressor to a location upstream the throttle bodyand compressor, the turbocharger efficiency can be temporarily reduced.Lowering the turbocharger efficiency lowers the possibility thatcylinder air charge will increase when EGR flow to the intake system istemporarily suspended.

Fuel injection timing may also be changed during an EGR valve statetransition. In one example, fuel injection timing may move frominjecting fuel while the intake valve is closed to a time when theintake valve is open. After the engine actuators are adjusted tocompensate for the EGR valve state transition the routine exits.

If the routine proceeded to step 213 from step 209, the routinedetermines the amount of adjustment to apply to the EGR valve inresponse to present engine operating conditions determined in step 201.In one embodiment, an amount of EGR is looked up from empirical datastored in a table. The table output is a mass flow rate of EGR goinginto the intake system at the present engine speed and torque demand,for example. The EGR valve is moved to a mapped position that is lookedup in response to engine speed and engine torque demand. The routinethen determines the pressure drop across an orifice to determine theactual flow through the EGR path. The EGR valve position is thenadjusted in response to the difference between the desired EGR flow rateand the actual EGR flow rate. After the EGR position is adjusted theroutine exits.

If the routine proceeded to step 215 from step 207, the routinedetermines if an EGR valve state transition is in progress. If a statetransition is in progress, the routine proceeds to step 217. If not, theroutine proceeds to step 219.

At step 217, the EGR valve state is in the process of changing from acondition where exhaust gas is delivered from a location upstream thecompressor and throttle body to a location downstream the compressor andthrottle body, and the EGR valve can be positioned briefly in the closedstate or in a position at which less exhaust gas is delivered to theintake system than when the engine is operating at substantially similarconditions. Briefly stopping or reducing the flow of exhaust gas fromthe exhaust manifold/pipe during a condition where the state of the EGRvalve is changed from delivering exhaust gas from upstream thecompressor to a location downstream the compressor allows time foradditional air to enter the intake system near the new EGR flow entrypoint. The additional air can then be combined with EGR at thedownstream EGR introduction location so that the air and exhaust gasentering the cylinder is substantially the same as before the EGR valvestate transition. If the same amount of exhaust were to flow to thedownstream EGR introduction location at the time that the EGR valvestate changed, then the level of exhaust gas entering the cylinder wouldtemporarily increase potentially resulting in less engine torque and anair-fuel ratio deviation.

When exhaust gas delivery to the intake system is switched from alocation upstream the throttle body and compressor to a locationdownstream the throttle body and compressor, the throttle plate positionmay also adjusted by briefly increasing the throttle opening amount.Increasing the throttle opening amount allows substantially the same aircharge to be drawn into engine cylinders after the EGR valve statechange as before the EGR valve state change. If the throttle positionwere to remain at substantially the same position during the EGR valvestate change, then less air may enter the engine because of the manifoldpressure increase that may be created by activating EGR flow downstreamfrom the throttle. As previously described, the change in throttleposition can be looked up from empirically determined tables or frommodels.

Cylinder spark advance can also be adjusted during an EGR valve statetransition when the exhaust delivery location in the intake system ischanged from a location upstream the compressor and throttle body to alocation downstream the throttle body and compressor. During the EGRvalve state transition the crankshaft angle at which spark is deliveredto a cylinder can be advanced or maintained to control the engine torqueduring the valve transition when the amount of exhaust entering enginecylinders may briefly change. Advancing the spark can increase enginetorque. The amount of spark advance and the spark advance duration maybe empirically determined and captured in tables or functions that areinterpreted during an EGR valve state transition. The tables can beindexed by engine operating conditions so that different amounts anddurations of spark advance can be implemented for different engineoperating conditions.

Turbocharger efficiency can be increased when the EGR valve state ischanged from delivering exhaust gas from an intake system location thatis upstream the throttle body and compressor to location that isdownstream the throttle body and compressor. In this example, theturbocharger efficiency may be increased during the EGR valve statetransition.

Referring now to step 219, the routine determines the amount ofadjustment to apply to the EGR valve in response to present engineoperating conditions determined in step 201. In one embodiment, anamount of EGR is looked up from empirical data stored in a table. Thetable output is a mass flow rate of EGR going into the intake system atthe present engine speed and torque demand, for example. The EGR valveis moved to a mapped position that is looked up in response to enginespeed and engine torque demand. The routine then determines the pressuredrop across an orifice to determine the actual flow through the EGRpath. The EGR valve position is then adjusted in response to thedifference between the desired EGR flow rate and the actual EGR flowrate. After the EGR position is adjusted the routine exits.

Referring now to FIG. 3 a, a plot of an engine EGR mode map that isdescribed in relation to engine operating conditions is shown. The plothas an x-axis that represents engine operating speed, wherein enginespeed increases from left to right. The y-axis represents desired ordemanded engine torque. The amount of demanded engine torque increasesfrom the plot's bottom to top. It should be noted that the availableengine speed and torque demand will vary with engine application. Assuch, the illustrated plot is meant to describe EGR flow modes and notto limit the system and method to any particular engine.

The engine EGR mode map is shown having two separate regions, 301 and302. When the engine operates in region 302, engine exhaust gases aredirected to a location in the intake system upstream of a compressor.When the engine is operated in region 301, engine exhaust gases aredirected to a location in the intake system downstream of thecompressor.

Region 302 represents engine operating conditions where engine speed islow and engine load (Engine load is related to the theoretical amount ofair a cylinder can hold at a given pressure; it is typically scaled from0-1, where 1 represents that the cylinder contains the theoretical limitof air amount) or torque demand is high. The size and shape of region302 may vary depending on engine design and configuration. In oneembodiment, the region's boundaries are determined by operating theengine with EGR flowing to a location in the intake system downstreamfrom the compressor. The boundary is made at engine conditions where EGRflow is limited to a value that is less than desired, or where the EGRflow varies more than a desired amount. Thus, when the operator requeststhat the engine move across the boundary between region 301 and region302, the location at which EGR enters the intake system is moved fromdownstream the compressor to upstream the compressor.

By changing the location at which EGR enters the engine's intake system,engine emissions and fuel consumption may be reduced. For example, EGRcan be delivered to the intake system at a location upstream acompressor when pressure in the intake manifold rises above pressure inthe exhaust system. Thus, the benefits of EGR can be continued duringengine operating conditions that may not otherwise permit theintroduction of EGR to the engine.

Referring now to FIG. 3 b, a plot of an alternative engine EGR mode mapis shown. The x and y axes are similar to those described in FIG. 3 a.

The engine EGR mode map is shown having two separate regions, 310 and311. When the engine operates in region 311, engine exhaust gases aredirected to a location in the intake system upstream of a compressor.When the engine is operated in region 310, engine exhaust gases aredirected to a location in the intake system downstream of thecompressor.

Region 311 represents engine operating conditions where engine load ortorque demand is high. The torque demand at the boundary between region310 and 311 may vary depending on engine design and construction.Boundary at region 311 includes high and low engine speeds where theengine is operated above a predetermined torque demand. When EGR isdelivered according to the bounds of region 311, it is possible to flowEGR to the engine when intake manifold pressure is high. Thus, theamount of EGR delivered to the engine at high load can be increased ascompared to a system that utilizes a single entry point to the engine'sintake system.

Referring now to FIG. 4, a plot of signals of interest during an EGRvalve state change is shown. The x-axis represents time for allsubplots. Time begins at zero and increases from left to right.Beginning from the top and moving toward the bottom, the first subplotshows a simulated example of EGR valve position during an operatingcycle of an engine. The zero corresponds to a valve position at whichthere is substantially zero exhaust gas recirculation flow. The bottom100 label indicates the location where the EGR valve is fully open andwhere exhaust gases are directed to the intake system at a locationdownstream the compressor. The top 100 label indicates the locationwhere the EGR valve is fully open and where exhaust gases are directedto the intake system at a location upstream the compressor. The nextsubplot illustrates EGR flow into the engine during the same timeperiod. The following subplot illustrates engine torque demand (0 beingzero torque demand and 1 being 100% torque demand) during the sameperiod followed by spark advance and throttle position (0 beingtop-dead-center compressor stroke and 35 being advanced 35 crankshaftangle degrees from top-dead-center compression stroke).

At time zero, the EGR valve position is partially open for deliveringexhaust gas to a location in the intake manifold that is downstream thecompressor. The EGR valve position continues to open as vertical marker401 is approached in time. The amount of exhaust gas entering the engineat time zero is low and increases as time approaches vertical marker401. Similarly, the engine torque demand and throttle at time zero arelow and increase as time approaches vertical marker 401. Spark isinitially advanced and is retarded as engine load increases.

Vertical marker 401 represents a point in time at which the enginetorque demand reaches a predetermined level. When the engine torquedemand reaches the predetermined level, the EGR valve switches state.The EGR valve state change is identified by the EGR valve trajectorymoving from below the zero position to above the zero position. Exhaustgas flowing into the intake system moves from an entry point downstreamthe compressor to a location upstream the compressor. Recognize that theEGR valve goes through a zero flow condition before exhaust begins toflow upstream the compressor. Consequently, exhaust gases temporarilystop flowing from the exhaust manifold/pipe to the intake system duringthe EGR valve state transition. When the EGR state position is changed,the EGR valve opening amount is made to purposefully overshoot theposition that yields the desired exhaust flow rate at steady stateconditions. By commanding the EGR valve to overshoot the desired exhaustgas steady state flow rate, additional exhaust gas can be introducedupstream the compressor. Introducing additional exhaust gas to theintake system allows more exhaust gas to mix with air that occupiesintake duct volume between the upstream and downstream exhaust gas entrylocations in the intake system.

The percent exhaust gas entering the cylinder increases as verticalmarker 401 is approached. The increased exhaust flow corresponds to alarger EGR valve opening amount. Likewise, engine torque demand, andthrottle position are shown increasing as time approaches verticalmarker 401. The illustrated sequence represents a condition when theoperator increases engine torque demand at low engine speed.

At vertical marker 401, the EGR valve changes state and compensation isprovided by adjusting the throttle position and the spark advance. Thethrottle position is decreased and then is increased shortly thereafter.The throttle position is adjusted to compensate for the change in intakemanifold pressure that may occur when the exhaust gas introductionlocation is changed. The throttle opening amount is adjusted to controlengine torque during the EGR valve state change. By adjusting thethrottle, air entering the cylinders is adjusted so that the torqueoutput from the engine is near the desired engine torque.

The amount of exhaust gas entering the engine cylinders increases fromtime zero to the time at vertical marker 401. When the EGR valve stateis transitioned, the amount of exhaust entering the cylinders is brieflyreduced because exhaust gases entering the intake system from upstreamthe compressor cannot instantaneously mix with the air that occupies theintake system volume between the upstream and downstream exhaust gasentry locations.

Engine spark may also be adjusted during the EGR valve state change.Spark angle advance is shown decreasing at the time approaching verticalmarker 401. As the EGR valve state is changed, spark is retarded.Retarding the spark provides a way to adjust engine torque when the EGRvalve state is changed. As previously described, engine torque mayincrease as exhaust gas entering the intake system downstream thecompressor is deactivated. Retarding the spark angle can be used tocompensate an increase in cylinder air charge that may accompany an EGRvalve state change.

Between vertical marker 401 and 403, the signals depicted in thesubplots are adjusted in relation to engine operating conditions. Theexample in the figure represents engine operating conditions that remainsubstantially constant between vertical marker 401 and 403.

At vertical marker 403, the engine torque demand is decreased and theEGR valve state changes shortly thereafter. Intake manifold pressure isreduced when the engine torque demand is reduced, thereby facilitatingexhaust gas flowing into the intake system at a location downstream fromthe compressor. During the EGR valve state change, the EGR valve may bebriefly held at a closed position where exhaust flow through the valveis substantially zero, see label 407. The amount of time that the valvestays at the zero flow position may depend on engine operatingconditions and the volume of the intake system between the upstream anddownstream exhaust gas entry locations.

The amount of exhaust gas entering the cylinders does notinstantaneously change when the EGR valve state changes. Exhaust gascontinues to flow from the exhaust gas entry location upstream thecompressor until the exhaust gas is inducted into the engine cylinderand fresh air displaces the exhaust gas. The amount of exhaust gasentering the engine cylinders is then reduced to a level that is relatedto the EGR valve position.

The engine throttle opening amount is reduced with engine torque demand.However, the throttle opening amount is briefly increased after verticalmarker 403 and during the EGR valve state transition so that enginetorque is smoothed. Opening the engine throttle allows fresh air to mixwith the exhaust enriched charge mixture so that the amount of exhaustentering engine cylinders does not substantially increase. Opening thethrottle can reduce the possibility of engine misfire when engine torquedemand is reduced and when an EGR valve state change occurs.

Engine spark advance is increased as engine load decreases. Although notshown, it is possible to briefly advance or retard spark so that engineemissions or torque may be controlled.

Engine torque is gradually increased between vertical markers 403 and405. At vertical marker 405 the requested engine torque reaches apredetermined level and the EGR valve state is changed so that exhaustgas can continue to flow into engine cylinders. Engine actuators areadjusted similarly as shown at vertical marker 403.

The methods, routines, and configurations disclosed herein are exemplaryand should not be considered limiting because numerous variations arepossible. For example, the above disclosure may be applied to I3, I4,I5, V6, V8, V10, and V12 engines operating in natural gas, gasoline,diesel, or alternative fuel configurations.

The following claims point out certain combinations regarded as noveland nonobvious. Certain claims may refer to “an” element or “a first”element or equivalent. However, such claims should be understood toinclude incorporation of one or more elements, neither requiring norexcluding two or more such elements. Other variations or combinations ofclaims may be claimed through amendment of the present claims or throughpresentation of new claims in a related application. The subject matterof these claims should be regarded as being included within the subjectmatter of the present disclosure.

1. A system for providing EGR to an internal combustion engine, thesystem comprising: an internal combustion engine; a turbochargercomprising a compressor and a turbine; an EGR valve capable of directingexhaust gases from the engine's exhaust to a location in the engine'sintake system upstream of the compressor or to a location in theengine's intake system downstream of the compressor; and a controllerthat provides compensation when the state of the EGR valve changes froma condition supplying exhaust gases to downstream the compressor tosupplying exhaust gases to upstream the compressor.
 2. The system ofclaim 1 wherein the compensation comprises adjusting the spark timing ofthe internal combustion engine.
 3. The system of claim 1 furthercomprising said controller providing compensation when the state of theEGR valve changes from a condition supplying exhaust gases to upstreamthe compressor to supplying exhaust gases to downstream the compressor.4. The system of claim 1 wherein the compensation comprises adjustingthe position of the EGR valve to increase and then reduce the flow ofEGR through the EGR valve during the EGR valve state change.
 5. Thesystem of claim 1 wherein the compensation comprises adjusting enginevalve timing.
 6. The system of claim 1 wherein the compensationcomprises adjusting fuel timing to the engine.
 7. The system of claim 1wherein the compensation comprised adjusting the turbocharger boostpressure.
 8. The system of claim 1 wherein a three-way catalyst isinstalled in a duct between the engine's exhaust system and the upstreamside of the compressor.
 9. The system of claim 1 wherein a three-waycatalyst is installed in an exhaust duct upstream of the EGR valve andupstream of the compressor.
 10. A system for providing EGR to aninternal combustion engine, the system comprising: an internalcombustion engine having an exhaust duct and an intake duct; aturbocharger having a compressor and turbine, the turbocharger coupledto the internal combustion engine by way of the exhaust duct and theintake duct; an EGR valve configured such that the inlet of the EGRvalve is in communication with the exhaust duct upstream of theturbocharger and such that one outlet of the EGR valve is incommunication with the intake duct downstream of the compressor, andsuch that a different outlet of the EGR valve is in communication withthe intake duct upstream of the compressor; and a controller thatadjusts the position of the EGR valve in response to a pressuredifferential.
 11. The system of claim 10 wherein the pressuredifferential is a pressure difference between an intake manifold and anexhaust duct.
 12. The system of claim 10 wherein the controller furtheradjusts engine valve timing in relation to the position of the EGRvalve.
 13. The system of claim 10 wherein the pressure differential isdetermined across an orifice.
 14. The system of claim 10 wherein theefficiency of the turbocharger is adjusted when the state of the EGRswitches from delivering exhaust gases to the intake duct upstream ofthe compressor to delivering exhaust gases to the intake duct downstreamof the compressor.
 15. The system of claim 10 wherein the position ofthe EGR valve is further adjusted in response to engine speed or load.16. The system of claim 10 further comprising a catalyst locatedupstream of the EGR valve inlet or downstream the outlet of the EGRvalve that is in communication with the intake duct upstream of thecompressor.
 17. A method for providing EGR to an internal combustionengine, the method comprising: adjusting the position of an EGR valve toa first position to deliver exhaust gases upstream of a compressor at afirst pressure differential between an engine intake manifold and anengine exhaust duct; and adjusting the position of the EGR valve to asecond position to deliver exhaust gases downstream of the compressor ata second pressure differential between the engine intake manifold andthe engine exhaust duct.
 18. The method of claim 17 wherein a catalystis in communication with an outlet of the EGR valve and the upstreamside of the compressor.
 19. The method of claim 17 further comprisingadjusting valve timing of the engine as the EGR valve switches fromdelivering exhaust gases upstream the compressor to delivering exhaustgases downstream the compressor.
 20. The method of claim 17 furthercomprising adjusting engine spark advance as the EGR valve switches fromdelivering exhaust gases upstream the compressor to delivering exhaustgases downstream the compressor.
 21. The method of claim 17 furthercomprising adjusting engine throttle position as the EGR valve switchesfrom delivering exhaust gases upstream the compressor to deliveringexhaust gases downstream the compressor.
 22. A method for providing EGRto an internal combustion engine, the method comprising: adjusting theposition of an EGR valve so that exhaust gas flows into an engine intakesystem to a first position upstream of a compressor when engine speed islow and engine torque demand is high; and adjusting the position of theEGR valve so that exhaust gas flows into an engine intake system to asecond position downstream of the compressor when engine speed is highor when engine torque demand is low.
 23. The method of claim 22 whereinthe EGR valve is capable of directing exhaust gas to at least two paths.24. The method of claim 22 wherein the position of the EGR valve isadjusted in response to engine speed.
 25. The method of claim 22 whereinthe position of the EGR valve is adjusted in response to engine torquedemand.
 26. The method of claim 22 wherein the EGR valve is electricallycontrolled.